Container patch and method of formation

ABSTRACT

A patch, method of applying a patch, and an applicator device for application of the patch to cover the opening of a hole in a gable-top carton panel. The patch is made from a frangible laminate material and is welded to the underside of the carton panel, corresponding to the side in contact with the beverage contained therein. The welder is located outside the container and the patch is applied to the carton after bottom seal formation.

BACKGROUND OF THE INVENTION

[0001] The invention relates to a gable-top or other beverage containerwith a post forming applied straw patch or cover. The patch or cover isa weldable, frangible barrier material for the gable straw opening. Alsodisclosed is an inventive process for producing the frangible material,as well as a unique application for applying the cover to the gablestraw opening.

[0002] Previous methods for producing a straw opening have been based onapplying webs or types of barrier material to webs of a packagesubstrate. In limited cases where a local patch has been applied, thepatch has been a two or more part system where removal of a top cover orother manipulation was required to expose and precondition the strawopening so that it could be pierced.

[0003] In addition, local patch applications in current practice requiremuch higher penetration forces than extrusion over void manufacturingmethods.

[0004] The gable-top strawhole has to be visible, provide an oxygenbarrier, and be puncturable by a straw with comparable force to anaseptic juice package.

[0005] It is an objective of the present invention to provide a patch orcover for a strawhole opening in a gable-top container top that has asimilar appearance to an opening in an aseptic container.

[0006] It is an objective of the present invention to provide a patch orcover for a strawhole opening in a gable-top container that provides anoxygen barrier and is puncturable by a straw with comparable force to anaseptic juice container.

SUMMARY OF THE INVENTION

[0007] A patch or cover for a strawhole for a gable-top container, orthe like, including a piece of frangible barrier film applied to acarton after bottom formation. The frangible film is welded on theinside of the carton, with the welding energy being applied from theoutside (ultrasonic or induction) and travels through the paper laminateto produce a thermoplastic sea. The patch is applied by a smallapplication component which holds the patch for welding and can be usedfor small cartons.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a perspective view of a gable-top container having apatch embodying the present invention;

[0009]FIG. 2 is a view of an inside of a top panel of a gable top cartonhaving a patch welded thereon; and

[0010]FIG. 3 is a cross-section of the barrier laminate embodying thepatch of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0011] A finished package, such as a gable top container 10, is providedwith a die cut strawhole 12 covered by an internal patch 14circumadjacent to the strawhole on the product contact side 16 of thecontainer 10.

[0012] The patch 14 is composed of a barrier film 26, an aluminum foilstiffener layer 24, and a thermoplastic seal layer 22 which iscompatible with low density polyethylene seals. The layers 30 the patchmaterial are extrusion laminated together to provide resistance todelamination when in contact with beverages. The patch material ispuncturable with a 6 mm-2.54 cm diameter drinking straw made of 1 mil ofpolyolefin with a puncture force of less than 4 pounds.

[0013] The patch applicator means includes a tape metering device, a cutto length mechanism, a vacuum equipped mandrel for insertion of thepatch into the carton, and a welding energy source located outside ofthe package. By applying the patch after the carton bottom is formed,the possibility of damage through contact with a filling machine isminimized.

[0014] The following is a representative barrier structure set forth intabular form from inside (product contact) to seal layer 22. LayerMaterial Thickness Barrier film LDPE/EVOH/LDPE .001 inches Tie layerNucrel ® 4 lbs/3,000 sf Foil layer Aluminum Foil — Tie layer Nucrel ® 4lbs/3,000 sf Sear layer EVA 4 lbs/3,000 sf

[0015] The welded or sealed area or seal layer can cover the completepatch or only a thin perimeter of the patch material in contact with theinside layer of the carton.

[0016] Numerous patch material structures can be used including thosewhich are pigmented in a variety of colors or metallic. The shape of thepatch can vary and may include round, square, triangular, and the likeas desired. Likewise, the shape of the opening in the gable top canvary.

[0017] A “twist-cap” can be applied over the patch to allow for openingand pouring of the beverage instead of a straw.

[0018] The patch can be applied while the carton is in the web or blankform.

[0019] The patch and/or the carton wall can have different barrierproperties. (The carton wall need not have an aluminum foil barrier, butthe externally visible patch can.)

[0020] Through use of an ultrasonic filament welder, it is possible toapply small patches of thin material to the area of interest. Thesepatches are comparable to aseptic brick openings in appearance andfunction. However, no additional components need to be applied to thepatch area to allow functioning of a straw. Because the welding energyis transmitted through the carton instead of through the patch, it ispossible to use more dedicated membranes for the patch than in a typicaltwo piece application which applies heat through the patch.

[0021] The embodiments described above are exemplary of the subjectmatter of the invention. The invention can be interpreted by areasonable person skilled in the art to include modifications or changesand the invention is only limited by the scope of the appended claims.

What is claimed is:
 1. A patch for a gable-top carton openingcomprising: a laminate frangible material layer welded to an undersideof a gable-top carton panel, the laminate frangible material layercomprising a barrier layer, a foil layer and a thermoplastic seal layer.2. The patch for a gable-top carton opening as claimed in claim 1,wherein the patch is welded by ultrasonic or induction welding from anexterior of the carton panel to produce a seal between the underside ofthe carton panel and the thermoplastic seal layer of the laminatefrangible material layer.
 3. The patch for a gable-top carton opening asclaimed in claim 1, wherein the thermoplastic seal layer is present on aperimeter of the patch in contact with the underside of the cartonpanel.
 4. The patch for a gable-top carton opening as claimed in claim1, wherein the laminate frangible material layer is circumadjacent tothe opening.
 5. The patch for a gable-top carton opening as claimed inclaim 1, wherein the laminate frangible layer material is extrusionlaminated together.
 6. The patch for a gable-top carton opening asclaimed in claim 1, wherein the barrier layer is a three layer laminateof low density polyethylene, ethylene vinyl alcohol copolymer, and lowdensity polyethylene.
 7. The patch for a gable-top carton opening asclaimed in claim 1, wherein the foil layer is a layer of aluminum foil.8. The patch for a gable-top carton opening as claimed in claim 1,wherein the thermoplastic seal layer is a layer of ethylene vinylacetate.
 9. The patch for a gable-top carton opening as claimed in claim1, wherein the laminate frangible material layer further comprises anadhesive tie layers between the foil layer and the barrier layer, andthe foil layer and the thermoplastic seal layer.
 10. A method ofapplying a patch for an opening gable-top carton comprising the stepsof: welding the patch as claimed in claim 1 to the underside of thegable-top carton panel by welding with a device contained on an outsideof the carton.
 11. The method of applying a patch for an openinggable-top carton as claimed in claim 10, wherein the patch is welded tothe underside of the gabvle top carton panel after a carton bottom hasbeen formed.
 12. An application means for placing a patch over anopening in a gable-top carton comprising: i) a tape metering device toproduce a desire amount of patch; ii) a cut to length mechanism forcutting the patch into a desired shape; iii) a vacuum equipped mandrelfor insertion of the patch into the opening in the carton; and iv) awelding energy source located outside of the carton.
 13. The applicationmeans for placing a patch over an opening in a gable-top carton asclaimed in claim 12, wherein the welding energy source is an ultrasonicsource or an induction source.